Forms of tiotropium bromide and processes for preparation thereof

ABSTRACT

This invention relates to novel crystalline forms of tiotropium bromide, processes for preparing them, and their use in pharmaceutical formulations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.11/643,001, filed Dec. 19, 2006, which claims the benefit of the filingdate of U.S. Provisional Patent Application No. 60/752,672 filed Dec.19, 2005; U.S. Provisional Patent Application No. 60/754,530 filed Dec.27, 2005; U.S. Provisional Patent Application No. 60/761,437 filed Jan.23, 2006; U.S. Provisional Patent Application No. 60/774,051 filed onFeb. 15, 2006; U.S. Provisional Patent Application No. 60/780,310 filedMar. 7, 2006; U.S. Provisional Patent Application No. 60/832,189 filedJul. 20, 2006; U.S. Provisional Patent Application No. 60/851,223 filedOct. 12, 2006; and U.S. Provisional Patent Application No. 60/852,740filed Oct. 18, 2006, the disclosures of which are hereby incorporatedherein by reference.

BACKGROUND OF THE INVENTION

Tiotropium bromide is an anticholinergic with specificity for muscarinicreceptors. It therefore provides therapeutic benefit in the treatment ofasthma or chronic obstructive pulmonary disease (“COPD”).

The chemical name of Tiotropium bromide is(1α,2β,4β,5α,7β)-7-[(hydroxydi-2-thienylacetyl)oxy]-9,9-dimethyl-3-oxa-9-azoniatricyclo[3.3.1.0]nonanebromide or 6β,7β-epoxy-3β-hydroxy-8-methyl-1αH,5αH-tropanium bromide,di-2-thienylglycolate, and it has the following structure:

Tiotropium bromide is available commercially as SPIRIVA® HandiHaler®,available from Boehringer Ingelheim, in which it is present as themonohydrate form.

The preparation and crystallization of Tiotropium bromide from acetoneand methanol is disclosed in U.S. Pat. No. 5,610,163, providing aproduct having a melting point of 217-218° C.

Crystalline forms of Tiotropium bromide have also been reported invarious publications, such as U.S. Pat. No. 6,777,423, which describes acrystalline Tiotropium bromide monohydrate, U.S. Pat. No. 6,608,055,which describes a crystalline form of Tiotropium bromide anhydrate, WO2005/042527 which describes another crystalline form of anhydrousTiotropium bromide, and Publication No. IPCOM000143595D which describesa crystalline dichloromethane solvate of Tiotropium bromide.

The occurrence of different crystal forms (polymorphism) is a propertyof some molecules and molecular complexes. A single molecule, like theTiotropium bromide in the above formula, may give rise to a variety ofsolids having distinct physical properties like melting point, X-raydiffraction pattern, infrared absorption fingerprint and NMR spectrum.The differences in the physical properties of polymorphs result from theorientation and intermolecular interactions of adjacent molecules(complexes) in the bulk solid. Accordingly, polymorphs are distinctsolids sharing the same molecular formula, yet the polymorphs havedistinct advantageous and/or disadvantageous physical propertiescompared to other forms in the polymorph family. One of the mostimportant physical properties of pharmaceutical polymorphs is theirsolubility in aqueous solution.

The discovery of new crystalline polymorphic forms of a drug enlargesthe repertoire of materials that a formulation scientist has availablewith which to design a pharmaceutical dosage form of a drug with atargeted release profile and/or other desired characteristics.Therefore, there is a need to find additional crystalline forms ofTiotropium bromide.

Similar advantages can come from new solvates which may lead to otherpolymorphs, may provide a better way to produce still other forms orsolvates, or may provide processing advantages.

SUMMARY OF THE INVENTION

In one embodiment, the present invention provides a crystalline form ofTiotropium bromide, designated Form 1, characterized by a powder XRDpattern having peaks at about 8.7, 15.3, 15.5 and 25.3±0.2 degrees2-theta.

In another embodiment, the present invention provides a process forpreparing form 1 of Tiotropium bromide comprising crystallizingTiotropium bromide from a mixture comprising methanol and acetone havinga ratio of about 1/3 (vol/vol).

In yet another embodiment, the present invention provides a crystallineform of Tiotropium bromide, designated Form 2, characterized by a powderXRD pattern having peaks at about 23.1, 23.6, 24.1, 30.1 and 30.3±0.2degrees 2-theta.

In one embodiment, the present invention provides a process forpreparing form 2 of Tiotropium bromide comprising crystallizingTiotropium bromide from a mixture comprised of methanol and acetone at aratio of about 1/1 or about 3/1 (vol/vol).

In another embodiment, the present invention provides a crystalline formof Tiotropium bromide characterized by a powder XRD pattern having peaksat about 27.7, 27.8, 30.3 and 30.5±0.2 degrees 2-theta. This form can bedesignated as Form 6.

In yet another embodiment, the present invention provides a process forpreparing Form 6 of Tiotropium bromide by a process comprisingcrystallizing Tiotropium bromide from a mixture comprising acetic acid,methanol, and heptane.

In one embodiment, the present invention provides a crystalline form ofTiotropium bromide, designated Form 7, characterized by a powder XRDpattern having peaks at about 8.8, 9.0, 11.7 and 17.7±0.2 degrees2-theta.

In another embodiment, the present invention provides a process forpreparing Form 7 of Tiotropium bromide is prepared by a processcomprising crystallizing Tiotropium bromide from a mixture comprising asolvent mixture comprising of acetic acid and acetonitrile, andanti-solvent comprising of diisopropylether.

In yet another embodiment, the present invention provides a crystallineform of Tiotropium bromide, designated Form 8, characterized by a powderXRD pattern having peaks at about 16.2, 16.5, 28.0, and 28.3±0.2 degrees2-theta.

In one embodiment, the present invention provides n-propanol solvate ofTiotropium bromide.

In another embodiment, the present invention provides a crystallinehemi-n-propanol solvate of Tiotropium bromide, designated Form 9.

In another embodiment, the present invention provides hemi-n-propanolsolvate, designated Form 9, characterized by a single crystal XRD withthe following data: monoclinic crystal system; space group of Pc, (No.7); unit cell parameters: a, b, c: 13.4245, 12.0419, 13.6027 [Å],respectively, and alpha, beta, gamma: 90, 103.818, 90 [deg],respectively, and volume of: 2135.3 [Å³], Z of 4 for formulaC_(20.5)H₂₆BrNO_(4.5)S₂; and calculated density D of 1.53 [g/cm³]. Thesaid hemi-n-propanol solvate form may be also substantially identifiedby the calculated PXRD depicted in FIG. 10.

In yet another embodiment, the present invention provides a process forpreparing Tiotropium bromide Form 9 by crystallizing tiotropium bromidefrom n-propanol at isothermal conditions.

In one embodiment, the present invention provides crystalline form ofTiotropium bromide, designated Form 11, characterized by a powder XRDpattern with peaks at about 20.2, 26.5, 28.0, and 31.2±0.2 degrees2-theta.

In another embodiment, the present invention provides a crystallinehemi-n-propanol solvate of Tiotropium bromide, designated Form 12,characterized by a powder XRD pattern having peaks at about 20.9, 21.1,21.4 and 34.4±0.1 degrees 2-theta.

In yet another embodiment, the present invention provides a process forpreparing Tiotropium bromide Form 12 by providing a solution ofTiotropium bromide in n-propanol, and cooling to a temperature of about55° C. to about 25° C. to obtain a suspension.

In another embodiment, the present invention provides amorphousTiotropium bromide.

In another embodiment, the present invention provides a process forpreparing the amorphous form of Tiotropium bromide by a processcomprising lyophilizing a solution of Tiotropium bromide in water,t-butanol, methanol or mixtures thereof.

In yet another embodiment, the present invention offers a process forproducing the monohydrate form of Tiotropium bromide, characterized byPXRD with peaks at 8.9, 11.9, 13.5, 14.8, 16.7, 17.5, 20.3, 23.6, 24.1,and 26.9± degrees 2-theta by a process comprising providing a mixture ofTiotropium bromide in water.

In yet another embodiment, the present invention provides micronizedforms of Tiotropium bromide, designated 1, 2, 6, 7, 8, 9, 11, andamorphous.

In one embodiment, the present invention provides a process forpreparing a crystalline form of Tiotropium bromide, designated form 3,characterized by a powder XRD pattern with peaks at about 9.82, 10.91,13.45, 15.34, 17.93, 19.71, 20.90, and 21.45±0.2 degrees 2-theta, by aprocess comprising crystallizing Tiotropium bromide from a mixturecomprising methanol and acetone at a ratio of about 3/1 (vol/vol),respectively.

In another embodiment, the present invention provides a process forpreparing a crystalline form of Tiotropium bromide, designated Form 4,characterized by a powder XRD pattern with peaks at about 9.92, 11.03,13.41, 15.31, 18.10, 19.91, 20.94, and 21.41±0.2 degrees 2-theta by aprocess comprising crystallizing Tiotropium bromide from ethanol.

In yet another embodiment, the present invention provides a process forpreparing a crystalline form of Tiotropium bromide characterized by PXRDpattern with peaks at about 9.86, 10.97, 13.28, 15.28, 18.04, 19.80,20.71, 21.26±0.2 degrees 2-theta by a process comprising crystallizingTiotropium bromide from isopropanol.

In yet another embodiment, the present invention provides a process forpreparing a crystalline form of Tiotropium bromide, designated Form 10,characterized by a PXRD pattern with peaks at about 9.82, 10.88, 13.28,15.27, 16.39, 17.96, 19.67, 20.71, and 21.30±0.2 degrees 2-theta by aprocess comprising crystallizing Tiotropium bromide from n-butanol.

In one embodiment, the present invention provides pharmaceuticalformulations comprising at least one form of Tiotropium bromide,designated 1, 2, 6, 7, 8, 9, 11, or amorphous form, and apharmaceutically acceptable excipient.

In another embodiment, the present invention provides a process forpreparing pharmaceutical formulations comprising at least one form ofTiotropium bromide, designated 1, 2, 6, 7, 8, 9, 11, or amorphous form,and a pharmaceutically acceptable excipient.

In yet another embodiment, the present invention provides pharmaceuticalformulations comprising at least one form of Tiotropium bromide,designated 1, 2, 3, 4, 6, 7, 8, 9, 10, 11, or amorphous form, preparedaccording to the processes of the present invention, and apharmaceutically acceptable excipient.

In one embodiment, the present invention provides a process forpreparing pharmaceutical formulations comprising at least one form ofTiotropium bromide, designated Forms 1, 2, 3, 4, 6, 7, 8, 9, 10, 11, oramorphous form, prepared according to the processes of the presentinvention, and a pharmaceutically acceptable excipient.

In another embodiment, the present invention provides pharmaceuticalformulations comprising at least one form of micronized Tiotropiumbromide, designated 1, 2, 6, 7, 8, 9, 11, or amorphous and apharmaceutically acceptable excipient.

In yet another embodiment, the present invention provides a process forpreparing pharmaceutical formulations comprising at least one form ofmicronized Tiotropium bromide, designated 1, 2, 6, 7, 8, 9, 11, oramorphous and a pharmaceutically acceptable excipient.

In one embodiment, the present invention provides pharmaceuticalformulations comprising at least one form of micronized Tiotropiumbromide, designated 1, 2, 3, 4, 6, 7, 8, 9, 10, 11 or amorphous preparedaccording to the processes of the present invention, and apharmaceutically acceptable excipient.

In another embodiment, the present invention provides a process forpreparing pharmaceutical formulations comprising at least one form ofmicronized Tiotropium bromide, designated Forms 1, 2, 3, 4, 6, 7, 8, 9,10, 11, or amorphous, prepared according to the processes of the presentinvention, and a pharmaceutically acceptable excipient.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows the powder XRD pattern of Tiotropium bromide Form 1.

FIG. 2 shows the powder XRD pattern of Tiotropium bromide Form 2.

FIG. 3 shows the TGA curve of Tiotropium bromide Form 2.

FIG. 4 shows the powder XRD pattern of Tiotropium bromide Form 6.

FIG. 5 shows the TGA curve of Tiotropium bromide Form 6.

FIG. 6 shows the powder XRD pattern of Tiotropium bromide Form 7.

FIG. 7 shows the TGA curve of Tiotropium bromide Form 7.

FIG. 8 shows the powder XRD pattern of Tiotropium bromide Form 8.

FIG. 9 shows the TGA curve of Tiotropium bromide Form 8.

FIG. 10 shows the calculated powder XRD pattern of Tiotropium bromideForm 9.

FIG. 11 shows the ORTEP view of Tiotropium bromide Form 9.

FIG. 12 shows the powder XRD pattern of Tiotropium bromide Form 11.

FIG. 13 shows the TGA curve of Tiotropium bromide Form 11.

FIG. 14 shows the powder XRD pattern of Tiotropium bromide Form 12.

FIG. 15 shows the TGA curve of Tiotropium bromide Form 12.

FIG. 16 shows the powder XRD of amorphous Tiotropium bromide.

DETAILED DESCRIPTION

As used herein, the term “room temperature” refers to a temperatureranging from about 18° C. to about 25° C., preferably ranging from about20° C. to about 22° C.

The crystallization process disclosed in U.S. Pat. No. 5,610,163 failsto teach how to crystallize Tiotropium bromide to consistently obtainthe same crystalline form. Hence, the present invention not onlyprovides different crystalline and amorphous Tiotropium bromide but alsomethods for preparation thereof.

As used herein, the term “solvate” refers a crystalline substance thatincludes any solvent other than water at levels of more than 1%.

The present invention also provides crystalline Tiotropium bromide,designated Form 1, characterized by a powder XRD (“PXRD”) pattern withpeaks at about 8.7, 15.3, 15.5 and 25.3±0.2 degrees 2-theta. Form 1 maybe further characterized by a powder XRD pattern with peaks at about9.9, 13.3, 18.0, 20.2 and 24.2±0.2 degrees 2-theta. Form 1 may also besubstantially identified by the PXRD pattern depicted in FIG. 1. Thoseskilled in the art would recognize that Form 1 may be characterized byother methods including, but not limited to, solid state NMR, FTIR, andRaman spectroscopy.

Form 1 may be a solvated form of Tiotropium bromide, preferably amethanolate. Crystalline Form 1 of Tiotropium bromide may be provided ina relatively pure form with no more than about 10% of any other form ofTiotropium bromide present, preferably with no more than about 5% of anyother form of Tiotropium bromide as measured by PXRD. Preferably,crystalline Form 1 of Tiotropium bromide may be provided in a relativelypure form with no more than about 10% of Tiotropium bromide monohydrate,preferably with no more than about 5% of Tiotropium bromide monohydrateas measured by PXRD.

The said form 1 of Tiotropium bromide is prepared by a processcomprising crystallizing Tiotropium bromide from a mixture comprisingmethanol and acetone having a ratio of about 1/3 (vol/vol).

The Tiotropium bromide, used for the above crystallization process, aswell as for the following crystallization processes, described in thisapplication, can be obtained by any method known to a skilled artisan.For example, it can be obtained by the method disclosed in U.S. Pat. No.5,610,163.

The crystallization is done by a process comprising providing a solutionof Tiotropium bromide in a mixture comprising methanol and acetonehaving a ratio of about 1/3 (vol/vol), and cooling the solution toobtain a suspension.

The solution of Tiotropium bromide is provided by combining Tiotropiumbromide and a mixture comprising methanol and acetone having a ratio ofabout 1/3 (vol/vol), and heating. Preferably, the heating is done attemperature of about 50° C. to about 60° C., more preferably, to about57° C.

Typically, the solution is cooled to induce precipitation of thecrystalline form. Preferably, the solution is cooled to a temperature ofabout −6° C. to about −14° C., more preferably, to about −10° C. In amost preferred embodiment, the cooling is performed gradually so thatthe solution is cooled to a first temperature ranging from about 25° C.to about 20° C., preferably at a temperature of about 21° C., followedby cooling to a second temperature ranging from about −6° C. to about−14° C. Preferably, the gradual cooling is performed over a period ofabout 3 hours. Further cooling to a temperature of about −10° C. is,preferably, performed over a period of about 5 minutes.

The suspension may be maintained for at least about 3 hours, to increasethe yield of the precipitated crystalline form.

The process for preparing form 1 may further comprise recovering thecrystalline form from the suspension. The recovery may be done by anymethod known in the art, such as filtering, followed by drying underreduced pressure for at least 7 hours.

The present invention further provides crystalline Tiotropium bromide,designated Form 2, characterized by a PXRD pattern with peaks at about23.1, 23.6, 24.1, 30.1 and 30.3±0.2 degrees 2-theta. Form 2 may befurther characterized by a PXRD pattern with peaks at about 9.9, 11.0,13.4, 15.3, 18.1, 19.9, 21.4, 24.7, 25.2, 26.0 and 27.2±0.2 degrees2-theta. Form 2 may be also substantially identified by the PXRD patterndepicted in FIG. 2. Form 2 may also be characterized by a weight lossstep at about 160° C., of about 0.8% to about 2.3%, by thermalgravimetric analysis (“TGA”). Form 2 may be also substantiallyidentified by the TGA curve depicted in FIG. 3. Form 2 may be alsocharacterized by a differential scanning calorimetry (“DSC”) thermogramhaving a first endothermic peak at about 144° C. and a secondendothermic peak at about 228° C. Tiotropium bromide Form 2 mayadditionally be characterized by a melting point of about 207.6° C.Those skilled in the art would recognize that Form 2 may becharacterized by other methods including, but not limited to, solidstate NMR, FTIR, and Raman spectroscopy.

Form 2 may be a solvated form of Tiotropium bromide, preferably amethanolate solvate. Preferably, the amount of methanol as measured bygas chromatography (“GC”) is about 4.1%. Crystalline Form 2 ofTiotropium bromide may be provided in a relatively pure form with nomore than about 10% of any other form of Tiotropium bromide, preferablywith no more than about 5% of any other form of Tiotropium bromide asmeasured by PXRD. Preferably, crystalline Form 2 of Tiotropium bromidemay be provided in a relatively pure form with no more than about 10% ofTiotropium bromide monohydrate, preferably with no more than about 5% ofTiotropium bromide monohydrate, as measured by PXRD.

The said form 2 of Tiotropium bromide is prepared by a processcomprising crystallizing Tiotropium bromide from a mixture comprisingmethanol and acetone at a ratio of about 1/1 or about 3/1 (vol/vol).

The crystallization is done by a process comprising providing a solutionof Tiotropium bromide in a mixture comprising methanol and acetonehaving a ratio of about 1/1 or about 3/1 (vol/vol), and cooling thesolution to obtain a suspension.

The solution of Tiotropium bromide is provided by combining Tiotropiumbromide and a mixture comprising methanol and acetone having a ratio ofabout 1/1 to about 3/1 (vol/vol), and heating. Preferably, the heatingis done to a temperature of about 50° C. to about 70° C., morepreferably, to about 60° C.

Typically, the solution is cooled to induce precipitation of thecrystalline form. Preferably, cooling is to a temperature of about 25°C. to about 20° C. Preferably, this temperature range is reached over aperiod of about 3 hours. The suspension may be maintained for at leastabout 2 hours, to increase the yield of the precipitated crystallineform.

The process for preparing form 2 may further comprise recovering thecrystalline form from the suspension. The recovery may be done by anymethod known in the art, such as filtering, followed by drying underreduced pressure for at least 7 hours.

The present invention further provides crystalline Tiotropium bromidecharacterized by a PXRD pattern with peaks at about 27.7, 27.8, 30.3 and30.5±0.2 degrees 2-theta. This form can be designated as Form 6. ThisForm may be further characterized by a PXRD pattern with peaks at about9.9, 11.0, 13.3, 15.3, 18.1, 19.9 and 21.3±0.2 degrees 2-theta. Form 6may be also substantially identified by the PXRD pattern depicted inFIG. 4. Form 6 may be further characterized by weight loss step at about160° C., of about 5.3% to about 5.7%, by TGA, wherein this levelcorresponds to the theoretical value of Tiotropium bromide hemi-aceticacid solvate. Form 6 may be also substantially identified by the TGAcurve depicted in FIG. 5. Form 6 may be also characterized by a DSCthermogram having a first endothermic peak ranging from about 146° C. toabout 150° C. and a second endothermic peak ranging from about 227° C.to about 228° C. Those skilled in the art would recognize that Form 6may be characterized by other methods including, but not limited to,solid state NMR, FTIR, and Raman spectroscopy.

Form 6 may be a solvated form of Tiotropium bromide, preferably anacetic acid solvate, more preferably a hemi-acetic acid solvate.Preferably, the amount of acetic acid as measured by GC is of about5.4%. Crystalline Form 6 of Tiotropium bromide may be provided in arelatively pure form with no more than about 10% of any other form ofTiotropium bromide, preferably with no more than about 5% of any otherform of Tiotropium bromide, as measured by PXRD. Preferably, crystallineForm 6 of Tiotropium bromide may be provided in a relatively pure formwith no more than about 10% of Tiotropium bromide monohydrate,preferably with no more than about 5% of Tiotropium bromide monohydrate,as measured by PXRD.

The form 6 of Tiotropium bromide is prepared by a process comprisingcrystallizing Tiotropium bromide from a mixture comprising acetic acid,methanol, and heptane.

The crystallization process comprises providing a first solution ofTiotropium bromide in a mixture comprising acetic acid and methanol;adding n-heptane to the first solution to obtain a second solution, andcooling the second solution to obtain a suspension.

The first solution of Tiotropium bromide is provided by combiningTiotropium bromide and a mixture comprising acetic acid and methanol,and heating.

The ratio of acetic acid and methanol in the first solution comprisingacetic acid and methanol is, preferably, of about 7/1 to about 7/2(vol/vol), respectively.

Preferably, the first mixture is heated to a temperature ranging fromabout 40° C. to about 50° C., more preferably, to a temperature of about45° C. Preferably, the heating is performed over a period of about 1.5hours.

Preferably, the addition of n-heptane to the first solution is donedrop-wise. Preferably, the drop-wise addition is done over a period ofat least about 20 to about 40 minutes. Preferably, the addition is doneat a temperature ranging from about 40° C. to about 50° C., morepreferably, at a temperature of about 45° C. After the addition ofn-heptane, the obtained second solution is maintained at theabove-referenced temperatures for about a half an hour to about onehour.

Typically, the second solution is cooled to induce precipitation of thecrystalline form. The second solution is cooled, preferably to atemperature ranging from about 30° C. to about 20° C., more preferably,to a temperature ranging from about 30° C. to about 23° C. to, obtain asuspension. The suspension may be maintained for at least about 3 hours,to increase the yield of the precipitated crystalline form.

The process for preparing form 6 may further comprise recovering thecrystalline form from the suspension. The recovery may be done by anymethod known in the art, such as filtering, washing the filtered formwith n-heptane and drying.

The present invention further provides crystalline Tiotropium bromide,designated Form 7, characterized by a PXRD pattern with peaks at about8.8, 9.0, 11.7 and 17.7±0.2 degrees 2-theta. Form 7 may be furthercharacterized by a PXRD pattern with peaks at about 13.4, 15.1, 15.3,15.6, 18.1 and 20.2±0.2 degrees 2-theta. Form 7 may be alsosubstantially identified by the PXRD pattern depicted in FIG. 6. Form 7may be further characterized by a weight loss of about 5.2%, by TGA.Form 7 may also be substantially identified by the TGA curve depicted inFIG. 7. Form 7 may also be characterized by a DSC thermogram having afirst endothermic peak at about 136° C. and a second endothermic peak atabout 228.0° C. Those skilled in the art would recognize that Form 7 maybe characterized by other methods including, but not limited to, solidstate NMR, FTIR, and Raman spectroscopy.

Form 7 may be a solvated form of Tiotropium bromide, preferably anacetic acid solvate. Preferably, the amount of acetic acid as measuredby GC is of about 1.7%. Crystalline Form 7 of Tiotropium bromide may beprovided in a relatively pure form with no more than about 10% of anyother form of Tiotropium bromide, preferably with no more than about 5%of any other form of Tiotropium bromide, as measured by PXRD.Preferably, crystalline Form 7 of Tiotropium bromide may be provided ina relatively pure form with no more than about 10% of Tiotropium bromidemonohydrate, preferably with no more than about 5% of Tiotropium bromidemonohydrate, as measured by PXRD.

The said form 7 of Tiotropium bromide is prepared by a processcomprising crystallizing Tiotropium bromide from a mixture comprising asolvent mixture comprising of acetic acid and acetonitrile, andanti-solvent comprising of diisopropylether.

The crystallization process comprises providing a solution of Tiotropiumbromide in the said solvent, and adding Diisopropylether to the solutionto obtain a suspension.

Preferably, the solution of Tiotropium bromide is provided by combiningTiotropium bromide and the said solvent, and heating.

The ratio of acetic acid and acetonitrile in the said solvent is,preferably, of about 1/4 to about 1/5 (vol/vol), respectively.

Preferably, heating is done to at a temperature ranging from about 40°C. to about 50° C. More preferably, the heating is performed at atemperature of about 45° C. Preferably, the heating is performed for aperiod of about 1.5 hours.

Preferably, the addition of diisopropylether to the solution isdrop-wise, more preferably over at least about 15 minutes. Preferably,the addition is done at a temperature ranging from about 40° C. to about50° C., more preferably, to a temperature of about 45° C. After theaddition of Diisopropylether, the obtained suspension is maintained atthe above-referenced temperatures for about an hour.

Typically the suspension is cooled to increase the yield of theprecipitated product. Preferably, cooling is done to a temperature offrom about 30° C. to about 20° C., more preferably, the solution iscooled to a temperature from about 30° C. to about 21° C. The cooling isdone for a period of at least 3 hours.

The process for preparing form 7 may further comprise recovering thecrystalline form from the suspension. The recovery may be done by anymethod known in the art, such as filtering, followed by washing thefiltered form with Diisopropylether and drying.

The present invention provides crystalline Tiotropium bromide,designated Form 8, characterized by a PXRD pattern with peaks at about16.2, 16.5, 28.0, and 28.3±0.2 degrees 2-theta. Form 8 may be furthercharacterized by a PXRD pattern with peaks at about 9.9, 11.0, 13.4,15.3, 17.9, 19.7, 20.9, and 21.4±0.2 degrees 2-theta. Form 8 may be alsosubstantially identified by the PXRD pattern depicted in FIG. 8. Form 8may be further characterized by weight loss of about 5.1%, by TGA. Form8 may be also substantially identified by the TGA pattern depicted inFIG. 9. Form 8 may also be characterized by a DSC thermogram having afirst endothermic peak at about 149° C. and a second endothermic peak atabout 226° C. Those skilled in the art would recognize that Form 8 maybe characterized by other methods including, but not limited to, solidstate NMR, FTIR, and Raman spectroscopy.

Form 8 may be a solvated form of Tiotropium bromide, preferablyalcoholate, and more preferably methanolate. Crystalline Form 8 ofTiotropium bromide may be provided in a relatively pure form with nomore than about 10% of any other form of Tiotropium bromide, preferablywith no more than about 5% of any other form of Tiotropium bromide, asmeasured by PXRD. Preferably, crystalline Form 8 of Tiotropium bromidemay be provided in a relatively pure form with no more than about 10% ofTiotropium bromide monohydrate, preferably with no more than about 5% ofTiotropium bromide monohydrate, as measured by PXRD.

Crystalline form 8 of Tiotropium bromide is prepared by a processcomprising crystallizing Tiotropium bromide from methanol.

The process comprises providing a solution of Tiotropium bromide inmethanol, and cooling the solution to obtain a suspension.

Preferably, the solution of Tiotropium bromide in methanol is providedby combining Tiotropium bromide and methanol, and heating to obtain asolution. Preferably, heating is done to a temperature ranging fromabout 61° C. to about 65° C. More preferably, the heating is done at atemperature of about 63° C. Preferably, the heating is performed for aperiod of about 1 hour.

Typically, the solution is cooled to induce precipitation of thecrystalline form. The solution is, preferably, cooled to a temperatureranging from about 27° C. to about 22° C. More preferably, the solutionis cooled to a temperature of about 22° C. Reaching the abovetemperature is done over a period of at least about 2 hours.

The obtained suspension may be maintained for at least about 3.5 hours,to increase the yield of the precipitated product.

The process for preparing crystalline form 8 may further compriserecovering the crystalline form from the suspension. The obtainedprecipitate may be recovered from the suspension by any method known inthe art, such as filtering, followed by washing the filtered form withmethanol and drying.

The present invention also provides n-propanol solvate of Tiotropiumbromide.

The present invention also provides crystalline Tiotropium bromidehemi-n-propanol solvate substantially identified by the calculated PXRDpattern depicted in FIG. 10. The crystalline n-propanolate solvate maybe further characterized by weight loss of about 5.9%, by TGA, whereinthis level corresponds to the theoretical value of hemi-n-propanolsolvate of Tiotropium bromide. The stiochiometric value ofhemi-n-propanolate is 5.9%. Crystalline hemi-n-propanol solvate ofTiotropium bromide may be provided in a relatively pure form with nomore than about 10% of any other form of Tiotropium bromide, preferablywith no more than about 5% of any other form of Tiotropium bromide, asmeasured by PXRD. Preferably, hemi-n-propanol solvate of Tiotropiumbromide may be provided in a relatively pure form with no more thanabout 10% of Tiotropium bromide monohydrate, preferably with no morethan about 5% of Tiotropium bromide monohydrate, as measured by PXRD.Those skilled in the art would recognize that Form 9 may becharacterized by other methods including, but not limited to, solidstate NMR, FTIR, and Raman spectroscopy.

The present invention provides hemi-n-propanol solvate, designated Form9, characterized by a single crystal XRD with the following data:monoclinic crystal system; space group of Pc, (No. 7); unit cellparameters: a, b, c: 13.42, 12.04, 13.60 [Å], respectively, and alpha,beta, gamma: 90, 103.8, 90 [deg], respectively, and volume of: 2135[Å³], Z of 4 for formula C_(20.5)H₂₆BrNO_(4.5)S₂; and calculated densityD of 1.53 [g/cm³]. The said hemi-n-propanol form may be alsosubstantially identified by the ORTEP view depicted in FIG. 11.

The present invention provides a process for preparing Tiotropiumbromide Form 9 characterized by a single crystal XRD with the followingdata: monoclinic crystal system; space group of Pc, (No. 7); unit cellparameters: a, b, c: 13.4245, 12.0419, 13.6027[A], respectively, andalpha, beta, gamma: 90, 103.818, 90 [deg], respectively, and volume of:2135.3 [Å³], Z of 4 for formula C_(20.5)H₂₆BrNO_(4.5)S₂; and calculateddensity D of 1.53 [g/cm³] by crystallizing tiotropium bromide fromn-propanol at isothermal conditions.

Typically, the term “isothermal conditions” refers to constanttemperature. Preferably, the isothermal condition for preparing form 9is a temperature of 25° C.

The process comprises providing a solution of Tiotropium bromide inn-propanol, cooling the solution to a temperature of 25° C. to obtain amixture, and maintaining the mixture at 25° C. for about 5 days.

Preferably, the solution of Tiotropium bromide in n-propanol is providedby combining Tiotropium bromide and n-propanol, and heating. The heatingis done, preferably, to a temperature of from about 80° C. to about 100°C., more preferably, to 97° C.

Typically, the solution is cooled to induce precipitation of singlecrystals.

The process for preparing form 9 may further comprise recovering thecrystalline form. The recovery may be done by any method known in theart, such as filtering, washing the filtered form and drying.

The present invention provides crystalline form of Tiotropium bromide,designated Form 11, characterized by a PXRD pattern with peaks at about20.2, 26.5, 28.0, and 31.2±0.2 degrees 2-theta. Form 11 may be furthercharacterized by a PXRD pattern with peaks at about 8.9, 15.6, 17.7,21.7, 23.4, and 24.3±0.2 degrees 2-theta. Form 11 may be alsosubstantially identified by the PXRD pattern depicted in FIG. 12. Form11 may be further characterized by weight loss of about <0.1%, by TGA.Form 11 may be also substantially identified by the TGA curve depictedin FIG. 13. Form 11 may be further characterized by a DSC thermogramhaving an endothermic peak at about 227° C. Those skilled in the artwould recognize that Form 11 may be characterized by other methodsincluding, but not limited to, solid state NMR, FTIR, and Ramanspectroscopy.

Form 11 may be an anhydrous form of Tiotropium bromide. Crystalline Form11 of Tiotropium bromide may be provided in a relatively pure form withno more than about 10% of any other form of Tiotropium bromide,preferably with no more than about 5% of any other form of Tiotropiumbromide, as measured by PXRD. Preferably, crystalline Form of Tiotropiumbromide may be provided in a relatively pure form with no more thanabout 10% of Tiotropium bromide monohydrate, preferably with no morethan about 5% of Tiotropium bromide monohydrate, as measured by PXRD.

Crystalline form 11 of Tiotropium bromide is prepared by a processcomprising heating any Tiotropium bromide solvate to a temperatureranging from about 160° C. to about 170° C.

Preferably, a Tiotropium bromide solvate is heated to a temperature ofabout 160° C. Preferably, the heating is done at for about 1 hour toabout 2 hours, more preferably for about 1 hour.

The present invention provides a crystalline hemi-n-propanol solvate ofTiotropium bromide, designated Form 12, characterized by a powder XRDpattern having peaks at about 20.9, 21.1, 21.4 and 34.4±0.1 degrees2-theta.

Form 12 may be further characterized by a PXRD pattern with peaks atabout 9.9, 11.0, 13.5, 15.3, 18.1, 19.9, 20.9, 21.1, 21.4, 23.9, 25.1,27.1, and 34.4±0.2 degrees 2-theta. Form 12 may be also substantiallyidentified by the PXRD pattern depicted in FIG. 14. Form 12 may befurther characterized by weight loss of about 5.9% at a temperature ofabout 125° C. to about 184° C., by TGA wherein this level corresponds tothe theoretical value of hemi-n-propanol solvate of Tiotropium bromide.Form 12 may be also substantially identified by the TGA curve depictedin FIG. 15. Form 12 may be further characterized by a DSC thermogramhaving a first endothermic peak at 158° C., and a second endothermicpeak at about 229° C. Those skilled in the art would recognize that Form12 may be characterized by other methods including, but not limited to,solid state NMR, FTIR, and Raman spectroscopy.

Tiotropium bromide Form 12 is prepared by a process comprising providinga solution of Tiotropium bromide in n-propanol, and cooling to atemperature of about 55° C. to about 25° C. to obtain a suspension.

Preferably, the solution of Tiotropium bromide in n-propanol is providedby combining Tiotropium bromide and n-propanol, and heating. The heatingis done, preferably, to a temperature of from about 80° C. to about 100°C., more preferably, to 97° C.

Typically, the solution is cooled to induce precipitation of the saidcrystalline form. The solution is cooled, preferably to a temperature offrom about 55° C. to about 25° C. Preferably, the cooling is donegradually. The gradual cooling is done by reaching a temperature ofabout 55° C., and then further cooling to a temperature of about 25° C.to about 21° C. Preferably, reaching 55° C. is done over a period ofabout 4 hours. Preferably, reaching a temperature of about 25° C. toabout 21° C. is done over a period of about 3 hours.

Preferably, the cooled suspension is further maintained for about 5 toabout 18 hours.

The process for preparing form 9 may further comprise recovering thecrystalline form from the suspension. The recovery may be done by anymethod known in the art, such as filtering, washing the filtered formand drying.

The present invention provides amorphous form of Tiotropium bromide. Theamorphous Tiotropium bromide may be substantially identified by the PXRDdepicted in FIG. 16. The amorphous form of Tiotropium bromide may bewith no more than about 10% of any other form of Tiotropium bromide,preferably with no more than about 5% of any other form of Tiotropiumbromide, as measured by PXRD. Preferably, the amorphous form ofTiotropium bromide may be provided in a relatively pure form with nomore than about 10% of Tiotropium bromide monohydrate, preferably withno more than about 5% of Tiotropium bromide monohydrate, as measured byPXRD.

The amorphous form of Tiotropium bromide is prepared by a processcomprising lyophilizing a solution of Tiotropium bromide in water,t-butanol, methanol or mixtures thereof.

Typically, any form of Tiotropium bromide can be used as a startingmaterial for the lyophilizing procedure. The methanolate forms ofTiotropium bromide, designated 1, 2, and 8, and the n-propanol solvateform of Tiotropium bromide, designated form 9, are preferred startingmaterial for the above process. Preferably, the solution is prepared bydissolving Tiotropium bromide in water, in t-butanol, in methanol or inmixtures thereof. Preferably, the dissolution is performed at atemperature of from about 20° C. to about 40° C. The obtained solutionmay be filtered prior to lyophilizing it. Lyophilization may be done forabout 24 to about 48 hours.

The present invention provides a process for preparing a crystallineform of Tiotropium bromide, designated form 3, characterized by a powderXRD pattern with peaks at about 9.82, 10.91, 13.45, 15.34, 17.93, 19.71,20.90, and 21.45±0.2 degrees 2-theta, by a process comprisingcrystallizing Tiotropium bromide from a mixture comprising methanol andacetone at a ratio of about 3/1 (vol/vol), respectively.

The crystallization process comprising providing a solution ofTiotropium bromide in a mixture comprising methanol and acetone at aratio of about 3/1 (vol/vol), respectively, and cooling the solution toobtain a suspension.

The solution is provided by combining Tiotropium bromide and a mixturecomprising methanol and acetone at a ratio of about 3/1 (vol/vol),respectively, and heating.

Preferably, the heating is to a temperature of about 50° C. to about 70°C., more preferably, to a temperature of about 60° C.

Typically, the solution is cooled to induce precipitation of thecrystalline form. Preferably, the cooling is to a temperature of aboutroom temperature to about −5° C. Preferably, when the cooling isperformed to a temperature lower than room temperature, that temperatureis reached over a period of about 5 minutes.

Preferably, the suspension may be maintained for at least about 3 hours,to increase the yield of the crystalline form. The process for preparingform 3 may further comprise recovering the crystalline form from thesuspension.

The process for preparing Form 3 may further comprise recovering form 3from the suspension. The recovery may be done by any method known in theart, such as filtering, and drying under nitrogen for about 30 minutes,followed by further drying under reduced pressure for at least about 15hours.

The present invention provides a process for preparing a crystallineform of Tiotropium bromide, designated form 10, characterized by a PXRDpattern with peaks at about 9.82, 10.88, 13.28, 15.27, 16.39, 17.96,19.67, 20.71, and 21.30±0.2 degrees 2-theta by a process comprisingcrystallizing Tiotropium bromide from n-butanol.

The process comprises providing a solution of Tiotropium bromide inn-butanol, and cooling the solution to obtain a suspension.

The solution is provided by combining Tiotropium bromide and n-butanol,and heating. Preferably, the heating is done to a temperature rangingfrom about 90° C. to about 96° C., more preferably, the heating is doneto a temperature of about 94° C. Preferably, heating to a temperatureranging from about 90° C. to about 96° C. is done for a period of about2.5 to 3 hours. Optionally, the hot solution may be filtered prior tocooling it.

Usually, the solution is cooled to induce precipitation of thecrystalline product. The solution is cooled, preferably to a temperatureranging from about 25° C. to about 20° C., more preferably, the solutionis cooled to a temperature of about 22° C. Reaching the abovetemperature is done over a period of at least about 6 hours.

The obtained suspension is maintained to increase the yield of thecrystallized product. Preferably, the suspension is maintained for atleast about 5 hours.

The process for preparing crystalline form 10 can further compriserecovering it from the suspension. The recovery may be done by anymethod known in the art, such as filtering, washing the filtered formwith n-butanol and drying.

The present invention provides a process for preparing a crystallineform of Tiotropium bromide, designated form 4, characterized by a powderXRD pattern with peaks at about 9.92, 11.03, 13.41, 15.31, 18.10, 19.91,20.94, and 21.41±0.2 degrees 2-theta by a process comprisingcrystallizing Tiotropium bromide from ethanol.

Preferably, the process comprises providing a solution of Tiotropiumbromide in ethanol, and cooling the solution to obtain a suspension.

The solution is provided by combining Tiotropium bromide and ethanol,and heating.

Preferably, the solution is heated to a temperature ranging from about70° C. to about 80° C. More preferably, the heating is done at atemperature ranging from about 73° C. to about 78° C.

Typically, the solution is cooled to induce precipitation of thecrystalline form. Preferably, the solution is cooled to roomtemperature. Preferably, the cooling to room temperature is performedover a period of about 5 hours. The obtained suspension is maintainedfor at least about 3 hours, to increase the yield of the crystallizedproduct.

The process for preparing the above crystalline form may furthercomprise a process for recovering the said crystalline from thesuspension. The recovery process may be done by any method known in theart, such as filtering, and drying under nitrogen for about 30 minutes,followed by further drying under reduced pressure for at least about 9hours.

The present invention provides a process for preparing a crystallineform of Tiotropium bromide characterized by PXRD pattern with peaks atabout 9.86, 10.97, 13.28, 15.28, 18.04, 19.80, 20.71, 21.26±0.2 degrees2-theta by a process comprising crystallizing Tiotropium bromide fromisopropanol.

The process comprises combining providing a solution of Tiotropiumbromide in isopropanol, and cooling the solution to obtain a suspension

The solution is provided by combining Tiotropium bromide andiso-propanol, and heating. Preferably, the heating is done to atemperature of from about 80° C. to about 100° C., more preferably, toabout 81° C. Preferably, heating the isopropanol combination to atemperature from about 80° C. to about 100° C. is done for a period ofabout 5 hours. Optionally, the hot solution may be filtered, prior tocooling it.

Typically, the solution is cooled to induce precipitation of thecrystalline. The solution is cooled, preferably to a temperature of fromabout 25° C. to about 21° C., more preferably, the solution is cooled toa temperature ranging from about 23° C. to about 25° C. Reaching theabove temperature is done over a period of at least about 4 hours,preferably from about 4 hours to about 5 hours.

The obtained suspension is maintained to increase the yield of thecrystallized product. Preferably, the suspension is maintained for atleast about 5 hours.

The process for preparing the said crystalline form can further compriserecovering it from the suspension. The recovery may be done by anymethod known in the art, such as filtering, washing the filtered formand drying.

The present invention offers a process for producing the monohydrateform of Tiotropium bromide characterized by PXRD with peaks at about8.9, 11.9, 13.5, 14.8, 16.7, 17.5, 20.3, 23.6, 24.1, and 26.9±0.2degrees 2-theta by a process comprising providing a mixture ofTiotropium bromide in water.

The starting Tiotropium bromide can be any form of Tiotropium bromide.Any form of Tiotropium bromide refers to Tiotropium bromide solvate,anhydrous and amorphous. Typically, Tiotropium bromide solvate refers toany solvated form of Tiotropium bromide. Preferably, the solvate form ofTiotropium bromide is selected from a group consisting of: alcoholateand acetic acid solvate. Preferably, the alcoholate is any alcoholatesolvate of Tiotropium bromide, more preferably, methanolate, ethanolate,n-propanol solvate, iso-propanolate, and n-butanolate, most preferably,n-propanol solvate and methanolate.

Preferably, the mixture is provided at room temperature. The process maycomprise a step of maintaining the mixture at room temperature for about4 to 8 hours.

The process for preparing the monohydrate may further compriserecovering the monohydrate from the mixture. The recovery may be done bya process comprising filtering the suspension, washing the filteredprecipitate of the monohydrate form of Tiotropium bromide, and dryingunder a stream of nitrogen.

The novel forms of Tiotropium bromide, designated, 1, 2, 6, 7, 8, 9, 11,and amorphous can be micronized to prepare material suitable forformulation. Typically, the term “suitable for formulation” in referenceto micronized Tiotropium bromide corresponds to Tiotropium bromidehaving at least 90% of the particles below 20 microns.

In one embodiment, the present invention provides micronized forms ofTiotropium bromide, designated 1, 2, 6, 7, 8, 9, 11, and amorphous.Typically, the term “micronized” refers to a substance wherein at least90% of the particles have a particle size of less than 20 microns.

The micronization process can, optionally, be followed by a processcomprising exposing the micronized form to a suitable solvent to restorethe initial content of solvent in the solvate. Usually, the term“suitable solvent” corresponds to the kind of solvent in the originalsolvated form.

The present invention provides pharmaceutical formulations comprising atleast one form of Tiotropium bromide, designated 1, 2, 6, 7, 8, 9, 11,or amorphous form, and a pharmaceutically acceptable excipient.

The present invention provides a process for preparing pharmaceuticalformulations comprising at least one form of Tiotropium bromide,designated 1, 2, 6, 7, 8, 9, 11, or amorphous form, and apharmaceutically acceptable excipient.

The present invention provides pharmaceutical formulations comprising atleast one form of Tiotropium bromide, designated 1, 2, 3, 4, 6, 7, 8, 9,10, 11 or amorphous form, prepared according to the processes of thepresent invention, and a pharmaceutically acceptable excipient.

The present invention provides a process for preparing pharmaceuticalformulations comprising at least one form of Tiotropium bromide,designated Forms 1, 2, 3, 4, 6, 7, 8, 9, 10, 11, or amorphous form,prepared according to the processes of the present invention, and apharmaceutically acceptable excipient.

The present invention provides pharmaceutical formulations comprising atleast one form of micronized Tiotropium bromide, designated 1, 2, 6, 7,8, 9, 11, or amorphous, and a pharmaceutically acceptable excipient.

The present invention provides a process for preparing pharmaceuticalformulations comprising at least one form of micronized Tiotropiumbromide, designated 1, 2, 6, 7, 8, 9, 11, or amorphous, and apharmaceutically acceptable excipient.

The present invention provides pharmaceutical formulations comprising atleast one form of micronized Tiotropium bromide, designated 1, 2, 3, 4,6, 7, 8, 9, 10, 11, or amorphous prepared according to the processes ofthe present invention, and a pharmaceutically acceptable excipient.

The present invention provides a process for preparing pharmaceuticalformulations comprising at least one form of micronized Tiotropiumbromide, designated Forms 1, 2, 3, 4, 6, 7, 8, 9, 10, 11, or amorphous,prepared according to the processes of the present invention, and apharmaceutically acceptable excipient.

The compositions of the invention include powders, granulates,aggregates and other solid compositions comprising any one of thedesignated Forms of Tiotropium bromide.

In addition, the solid formulations comprising the above forms ofTiotropium bromide of the present invention may further includediluents, such as cellulose-derived materials like powdered cellulose,microcrystalline cellulose, microfine cellulose, methyl cellulose, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose,hydroxypropylmethyl cellulose, carboxymethyl cellulose salts and othersubstituted and unsubstituted celluloses; starch; pregelatinized starch;inorganic diluents like calcium carbonate and calcium diphosphate andother diluents known to the pharmaceutical industry. Yet other suitablediluents include waxes, sugars and sugar alcohols like mannitol andsorbitol, acrylate polymers and copolymers, as well as pectin, dextrinand gelatin.

Further excipients that are suitable in the present invention includebinders, such as acacia gum, pregelatinized starch, sodium alginate,glucose and other binders used in wet and dry granulation and directcompression tableting processes. Excipients that also may be present ina solid formulation of the above forms of Tiotropium bromide furtherinclude disintegrants like sodium starch glycolate, crospovidone,low-substituted hydroxypropyl cellulose, and others. In addition,excipients may include tableting lubricants like magnesium and calciumstearate and sodium stearyl fumarate; flavorings; sweeteners andpreservatives.

The formulations may be administered orally, parenterally, (includingsubcutaneous, intramuscular, and intravenous), by inhalation andophthalmogically. Although the most suitable route in any given casewill depend on the nature and severity of the condition being treated,the most preferred route of the present invention is oral. Dosages maybe conveniently presented in unit dosage form and prepared by any of themethods well-known in the art of pharmacy.

Dosage forms include solid dosage forms, like tablets, powders,capsules, suppositories, sachets, troches and losenges as well as liquidsuspensions and elixirs. While the description is not intended to belimiting, the invention is also not intended to pertain to truesolutions of Tiotropium bromide whereupon the properties thatdistinguish the solid forms of Tiotropium bromide are lost. However, theuse of the novel forms to prepare such solutions (e.g. so as to deliver,in addition to Tiotropium bromide, a solvate to said solution in acertain ratio with a solvate) is considered to be within the scope ofthe invention.

Capsule dosages, of course, will contain the solid composition within acapsule which may be made of gelatin or other conventional encapsulatingmaterial. Tablets and powders may be coated. Also, tablets and powdersmay be coated with an enteric coating. The enteric coated powder formsmay have coatings including, but not limited to, phthalic acid celluloseacetate, hydroxypropylmethyl-cellulose phthalate, polyvinyl alcoholphthalate, carboxymethylethylcellulose, a copolymer of styrene andmaleic acid, a copolymer of methacrylic acid and methyl methacrylate,and like materials, and if desired, they may be employed with suitableplasticizers and/or extending agents. A coated tablet may have a coatingon the surface of the tablet or may be a tablet comprising a powder orgranules with an enteric-coating.

One skilled in the art would appreciate that there is a typical smallanalytical error involved in PXRD measurements, generally of the orderof about ±0.2 degrees 2-theta, or less, for each peak. Accordingly, PXRDpeak data herein are presented in the form of “a PXRD pattern with peaksat A, B, C, etc.±0.2 degrees 2-theta.” This indicates that, for thecrystalline form in question, the peak at A could, in a given instrumenton a given run, appear somewhere between A±0.2 degrees 2-theta, the peakat B could appear at B±0.2 degrees 2-theta, etc. Such small, unavoidableuncertainty in the identification of individual peaks does not translateinto uncertainty with respect to identifying individual crystallineforms since it is generally the particular combination of peaks withinthe specified ranges, not any one particular peak, that serves tounambiguously identify crystalline forms. In an alternative, the presentinvention provides the overall pattern which can also be usedindependently of the reported peak positions or peak heights.

Having described the invention with reference to certain preferredembodiments, other embodiments will become apparent to one skilled inthe art from consideration of the specification. The invention isfurther defined by reference to the following examples describing indetail the preparation of the composition and methods of use of theinvention. It will be apparent to those skilled in the art that manymodifications, both to materials and methods, may be practiced withoutdeparting from the scope of the invention.

Instruments and reagents utilized include:

EXAMPLES

Instrument: Agilent Technologies Mod. 6850 gas chromatograph

Column: DB-WAX, 30 m, 0.32 mm ID, 0.5 μm df

Detector: FID

Temperature 300° C. Hydrogen flow 30.0 mL/min Air flow 300.0 mL/minMakeup Helium; 30.0 mL/min (total flow)Inlet:

Mode Splitless Temperature 140° C. Pressure 9.00 psi Gas type HeliumPurge flow 60.0 mL/min Purge time 0.10 min Total flow 64.6 mL/minInjection volume 1.0 μLOven:

Initial temperature 40° C. Initial time 5.00 min Ramps Rate Final Final# (° C./min) temp(° C.) time 1 10.00 230 7.00 2 0.0 Run time 31.00 minWash Solvent: DimethylsulphoxideCheck for:

Disopropylether, n-Heptane, Acetone, Methanol, Dichloromethane, Ethanol,Acetonitrile, Acetic Acid.

Internal Standard Solution:

250 μL Dioxane→250 mL Dimethylsulphoxide.

Stock Standard Solution:

1 mL of each solvent to 100.0 mL with Internal Standard Solution.

Working Standard Solution:

1 mL Stock Standard Solution to 100.0 mL with Internal Standard Solution(0.1 μL/mL each solvent).

Sample Solution:

To 100 mg of Sample add 1 mL of Internal Standard Solution.

Powder X-Ray Diffraction:

Powder X-ray diffraction (“PXRD”) analysis using an ARL X-ray powderdiffractometer model XTRA-030, equipped with Peltier detector, and anX-ray source of Cu Kα radiation, wavelength: 1.54178 Å. The sample wasintroduced using round standard aluminum sample holder with round zerobackground quartz plate. Scanning parameters: Range: 2-40 deg. 2 θ,continuous Scan, Rate: 3 deg./min. The accuracy of peak positions isdefined as +/−0.2 degrees due to experimental differences likeinstrumentations, sample preparations etc. . . . .

Single Crystal XRD Method for Analysis of Tiotropium Bromide n-PropanolSolvate:

Data were collected on Xcalibur PX, Cu Kα using combined φ and ω scans.All non-hydrogen atoms were refined anisotropically, hydrogen atoms wererefined riding in expected geometric positions, OH hydrogen atoms werelocated from fourier maps. Data collection: CrysAlis RED (OxfordDiffraction, 2002); cell refinement: CrysAlis RED; data reduction:CrysAlis RED; program used to solve structure: SIR92 (Altomare et al.,1994); program used to refine structure: CRYSTALS (Betteridge et al.,2003)

Thermal Gravimetric Analysis (“TGA”)

TGA/SDTA 851, Mettler Toledo, Sample weight 7-15 mg.

Heating rate: 10° C./min., in N₂ stream: flow rate: 50 ml/min.

Scan range: 30-250° C.

Differential Scanning calorimetry (“DSC”)

DSC 822^(e)/700, Mettler Toledo, Sample weight: 3-5 mg.

Heating rate: 10° C./min., Number of holes of the crucible: 3 In N₂stream: flow rate=40 ml/min

Scan range: 30-250° C., 10° C./minutes heating rate.

Example 1 Preparation of Tiotropium Bromide Form 1

Tiotropium bromide (2.50 g) was dissolved at 57° C. with a mixture 1/3(V/V) of methanol/acetone (55 ml). The solution was heated to 57° C. forabout 30 min., and then, cooled to 21° C. in at least 3 hours (no solidformation observed) and was quickly cooled to −10° C. in about 5 min.The obtained suspension was maintained at −10° C. for at least 3 hours,and filtered on a sintered glass funnel and the solid was washed with1.0 mL of the mixture. Drying for 30 min. at 21° C. under N₂ flow andthen for 7 hours at 111° C. under reduced pressure (40 mbar), yielded0.01 g of Tiotropium bromide Form 1.

Example 2 Preparation of Tiotropium Bromide Form 2

Tiotropium bromide (2.50 g) was dissolved at 60° C. with a mixture 3/1(V/V) of methanol/acetone (13 ml). The solution was heated to 60° C. forabout 30 min and then cooled to 22° C. in at least 3 hours. The obtainedsuspension was maintained at 22° C. for at least 2 hours, and filteredon a sintered glass funnel and the solid was washed two times with 1.5mL of the mixture. Drying for 30 min. at 22° C. under N₂ flow and thenfor 7 hours at 111° C. under reduced pressure (40 mbar), yielded 1.19 gof Tiotropium bromide Form 2. TGA weight loss: 2.3%.

Example 3 Preparation of Tiotropium Bromide Form 2

Tiotropium bromide (1.00 g) was dissolved at 60° C. with a mixture 1/1(V/V) of methanol/acetone (8.5 ml). The solution was heated to 60° C.for about 30 min. and then cooled to 21° C. in at least 3 hours. Theobtained suspension was maintained at 21° C. for at least 3 hours, andfiltered on a sintered glass funnel and the solid was washed three timeswith 1.0 mL of the mixture. Drying for 30 min. at 21° C. under N₂ flowand then for 7 hours at 111° C. under reduced pressure (40 mbar),yielded 0.154 g of Tiotropium bromide Form 2. TGA weight loss: 0.8%.

Example 4 Preparation of Tiotropium Bromide Characterized by a PowderXRD Pattern with Peaks at about 9.82, 10.91, 13.45, 15.34, 17.93, 19.71,20.90, and 21.45±0.2 Degrees 2-Theta

Crude Tiotropium bromide (2.50 g) was dissolved at 60° C. with a mixture3/1 (V/V) of methanol/acetone (13 ml). The solution was heated to 60° C.for about 30 min and then was cooled to 22° C. in at least 3 hours. Theobtained suspension was maintained at 22° C. for at least 2 hours, andfiltered on a sintered glass funnel and the solid was washed two timeswith 1.5 mL of the mixture. Drying for 30 min. at 22° C. under N₂ flowyielded 1.40 g of Tiotropium bromide Form 3. TGA weight loss: 5.1%.

Example 5 Preparation of Tiotropium Bromide Characterized by a PowderXRD Pattern with Peaks at about 9.82, 10.91, 13.45, 15.34, 17.93, 19.71,20.90, and 21.45±0.2 Degrees 2-Theta

Crude Tiotropium bromide (2.50 g) was dissolved at 60° C. with a mixture3/1 (V/V) of methanol/acetone (13 ml). The solution was heated to 60° C.for about 30 min and then was cooled to 22° C. in at least 3 hours. Theobtained suspension was maintained at 22° C. for at least 2 hours, andfiltered on a sintered glass funnel and the solid was washed two timeswith 1.5 mL of the mixture. Drying for 30 min. at 22° C. under N₂ flowand then for 15 hours at 60° C. under reduced pressure, yielded 1.33 gof Tiotropium bromide Form 3. TGA weight loss: 4.3%.

Example 6 Preparation of Tiotropium Bromide Characterized by a PowderXRD Pattern with Peaks at about 9.82, 10.91, 13.45, 15.34, 17.93, 19.71,20.90, and 21.45±0.2 Degrees 2-Theta

Crude Tiotropium bromide (2.50 g) was dissolved at 60° C. with a mixture3/1 (V/V) of methanol/acetone (13 ml). The solution was heated to 60° C.for about 30 min., was quickly cooled to −5° C. (5 min.) and maintainedat −5° C. for at least 3 hours. The obtained suspension was filtered ona sintered glass funnel and the solid was washed with 1.0 mL of themixture. Drying for 30 min. at 21° C. under N₂ flow yielded 1.31 g ofTiotropium bromide Form 3. TGA weight loss: 4.5%.

Example 7 Preparation of Tiotropium Bromide Characterized by a PowderXRD Pattern with Peaks at about 9.92, 11.03, 13.41, 15.31, 18.10, 19.91,20.94, and 21.41±0.2 Degrees 2-Theta

Crude Tiotropium bromide (1.00 g) was dissolved in absolute ethanol (65ml) at 78° C. The solution was heated to 78° C. for about 30 min andthen was cooled to 22° C. in at least 6 hours. The obtained suspensionwas maintained at 22° C. for at least 3 hours, and filtered on asintered glass funnel and the solid was washed two times with absoluteethanol (2×1.0 ml). Drying for 30 min. at 22° C. under N₂ flow and thenfor 9 hours at 60° C. under reduced pressure (17 mbar), yielded 0.66 gof Tiotropium bromide Form 4. TGA weight loss: 4.8%. Stoichiometricvalue of hemi-ethanolate: 4.64%.

Example 8 Preparation of Tiotropium Bromide Characterized by a PowderXRD Pattern with Peaks at about 9.92, 11.03, 13.41, 15.31, 18.10, 19.91,20.94, and 21.41±0.2 Degrees 2-Theta

Crude Tiotropium bromide (0.80 g) was dissolved in ethanol 96% (18.4 ml)at 73° C. The solution was heated to 73° C. for about 1 hour and thenwas cooled to 23° C. in at least 5 hours. The obtained suspension wasmaintained at 23° C. for at least 3 hours, and filtered on a sinteredglass funnel and the solid was washed two times with ethanol 96% (2×1.5ml). Drying for 1.5 hours at 23° C. under N₂ flow and for 5 hours at 60°C. under reduced pressure (18 mbar), yielded 0.39 g of Tiotropiumbromide Form 4. TGA weight loss: 4.7%. Stoichiometric value ofhemi-ethanolate: 4.64%.

Example 9 Preparation of Tiotropium Bromide Form 6

Tiotropium bromide (1.00 g) was dissolved at 45° C. with a mixture 7/2(V/V) of acetic acid/methanol (11 ml), the solution was heated to 45° C.for 1.5 hours and n-heptane (2.75 ml) was then added drop-wise in atleast 20 min. The obtained solution was heated to 45° C. for one hour(no solid formation observed), was cooled to 23.5° C. in at least 3hours and the suspension was maintained at 23.5° C. for at least 3hours. After filtration on a sintered glass funnel, the solid was washedthree times with 3.0 mL of n-heptane. Drying for 16 hours at 60° C.under reduced pressure (18 mbar), yielded 0.67 g of Tiotropium bromideForm 6. TGA weight loss: 5.4%.

Example 10 Preparation of Tiotropium Bromide Form 6

Tiotropium bromide (0.50 g) was dissolved at 45° C. with a mixture 7/1(V/V) of acetic acid/methanol (10 ml), the solution was heated to 45° C.for 1.5 hours and n-heptane (2.5 ml) was then added drop-wise in atleast 15 min. The obtained solution was heated to 45° C. for 0.5 hour(no solid formation observed), was cooled to 28° C. in at least 3 hoursand the suspension was maintained at 28° C. for at least 3 hours. Afterfiltration on a sintered glass funnel, the solid was washed three timeswith 2.0 mL of n-heptane. Drying for 18 hours at 60° C. under reducedpressure (19 mbar) or for 7 hours at 90-100° C. at 18 mbar pressureyielded 0.29 g of Tiotropium bromide Form 6. TGA weight loss: 5.7%.

Example 11 Preparation of Tiotropium Bromide Form 7

Tiotropium bromide (0.60 g) was dissolved at 45° C. with a mixture 1/4(V/V) of acetic acid/acetonitrile (6.75 ml), the solution was heated to45° C. for one hour and diisopropylether (DIPE) (6.75 ml) was then addeddrop-wise in at least 15 min. The obtained suspension was heated to 45°C. for at least one hour, was cooled to 21.5° C. in at least 3 hours andwas maintained at 21.5° C. for at least 3 hours. After filtration on asintered glass funnel, the solid was washed three times with 1.8 mL ofdiisopropylether (DIPE). Drying for one hour at 21° C. under N₂ flow,yielded 0.40 g of Tiotropium bromide Form 7.

Example 12 Preparation of Tiotropium Bromide Form 8

Tiotropium bromide (0.80 g) was dissolved in methanol (3.4 ml) at 63° C.The solution was heated to 63° C. for about 1 hour and then was cooledto 22° C. in at least 2 hours. The obtained suspension was maintained at22° C. for at least 3.5 hours, and filtered through a sintered glassfunnel. The solid was washed two times with methanol (2×0.8 ml), anddried for 1 hour at 22° C. under N₂ flow, yielding 0.49 g of tiotropiumbromide Form 8. TGA weight loss: 5.1%.

Example 13 Preparation of Tiotropium Bromide Form 9

Tiotropium bromide (45 mg) was dissolved at 97° C. in n-propanol (4 ml).Then amylacetate (4 ml) was added to the hot solution of Tiotropiumbromide in n-propanol. Crystallisation for 5 days at isothermalconditions at 25° C. provided single crystals of tiotropium bromide Form9. Single crystal was trapped by sticky glue technique from the motherliquor on the top of a glass needle of the goniometer assembly andmeasured at 298 K.

Example 14 Preparation of Tiotropium Bromide

Tiotropium bromide (0.40 g) was dissolved in isopropanol (160 ml) at 81°C. The solution was heated to 81° C. for about 5 hour, filtered througha sintered glass funnel and then cooled to 23° C. in at least 4 hours.The obtained suspension was maintained at 23° C. for at least 5 hours,and filtered through a sintered glass funnel. The solid was washed twotimes with isopropanol (2×1.0 ml), and dried for 1 hour at 23° C. underN₂ flow and then for 5 hours at 60° C. under reduced pressure (18 mbar),yielding 0.23 g of tiotropium bromide. TGA weight loss: 6.0%.

Example 15 Preparation of Tiotropium Bromide Form 12

Tiotropium bromide (4 g) was dissolved at 97° C. in n-propanol (348 ml),then cooled to 55° C. in 4 h and from 55° C. to 25° C. in 3 h. Afterstirring for 12 h at 20-25° C. the suspension was filtered, dried at 45°C. for 20 h under reduced pressure and tiotropium bromide form 12 (3 g)were obtained.

Example 16 Preparation of Tiotropium Bromide Form 12

Tiotropium bromide (2 g) was dissolved at 83° C. in n-propanolcontaining 5% w/w water (60 ml), then cooled to 25° C. in 4 h. Afterstirring for 12 h at 20-25° C. the suspension was filtered, dried at 45°C. for 20 h under reduced pressure and tiotropium bromide form 12 (1.3g) was obtained.

Example 17 Preparation of Tiotropium Bromide Form 12

Tiotropium bromide (2 g) was dissolved at 85° C. in n-propanolcontaining 2% w/w water (58.5 ml), then cooled to 25° C. in 5 h. Afterstirring for 12 h at 20-25° C. the suspension was filtered, dried at 45°C. for 20 h under reduced pressure and tiotropium bromide form 12 (1.8g) was obtained.

Example 18 Preparation of Tiotropium Bromide Characterized by a PXRDPattern with Peaks at about 9.82, 10.88, 13.28, 15.27, 16.39, 17.96,19.67, 20.71, and 21.30±0.2 Degrees 2-Theta

Crude tiotropium bromide (0.40 g) was dissolved in n-butanol (70 ml) at94° C. The solution was heated to 94° C. for about 2.5 hour, filteredthrough a sintered glass funnel and then cooled to 22° C. in at least 6hours. The obtained suspension was maintained at 22° C. for at least 5hours, and filtered through a sintered glass funnel. The solid waswashed two times with n-butanol (2×1.0 ml), and dried for 3 hour at 22°C. under N₂ flow and then for 16.5 hours at 65° C. under reducedpressure (18 mbar), yielding 0.133 g of tiotropium bromide Form 10. TGAweight loss: 6.9%.

Example 19 Preparation of Tiotropium Bromide Form 11

Tiotropium bromide methanolate, hemi-n-buthanolate and hemi-acetic acidsolvate were heated in separate glass containers in an oven at 160° C.for 1 hour, then each substance was measured by XRD.

Example 20 Preparation of Amorphous Form of Tiotropium Bromide

1 g of Tiotropium bromide was dissolved at room temperature in 50 ml ofwater, it was then filtered (to get rid of small unsoluble particles)and put to lyophilization for 24 hours.

-   -   chamber vacuum: <20 μm Hg    -   chamber temperature during 24 hours: from −40° C. to 22° C.

Example 21 General Procedure for Preparing Tiotropium BromideMonohydrate

Tiotropium bromide is mixed with 80.7 mL of water and the mixture isstirred at r.t. for 4 h. The mixture is filtered and washed with 10 mLof water. The product is left on the filter under vacuum and undernitrogen at r.t. for 15 min, providing the monohydrate form.

Example 19 Preparation of Tiotropium Bromide Monohydrate

Tiotropium was suspended in water and the suspension was stirred at22-25° C. for 4 h. After that it was filtered and the solid was washedwith 10 mL of water. The product was left on the filter under vacuum andunder nitrogen at 20°-25° C. for 15′. The content of water on the samplewas 4.3% (TGA analysis).

Example 20 Preparation of Tiotropium Bromide Monohydrate from TiotropiumBromide Ethanolate

13.45 g of dry Tiotropium bromide ethanolate were suspended in 80.7 mLof water and the suspension was stirred at r.t. for 4 h. After it wasfiltered washing with 10 mL of water was conducted. The product was lefton the filter under vacuum and under nitrogen at r.t. for 15 min. 11.66g of monohydrate were obtained. The content of water on the sample was4.3% (TGA analysis).

Example 21 Micronization of Tiotropium Bromide

Tiotropium Bromide was micronized to obtain P.S.D target of:

-   -   Min. 80%<5.84 μm    -   Min. 70% between 0.6 and 10 microns    -   The micronizer in use was a Jet-mill MC 50 (made by        Micro-Macinazionne). 32°05′ angle nozzles were installed.    -   Nitrogen was used as the micronization gas.    -   Micronization air Pressure was 10 bars.    -   Feed rate was 0.2 kg/hr.    -   The micronized Tiotropium bromide obtained by the above process        has a PSD value:    -   80%≦5.84 μm    -   93.76% between 0.6 and 10 microns.

What is claimed is:
 1. A crystalline hemi-n-propanol solvate oftiotropium bromide characterized by a PXRD pattern as depicted in FIG.14.
 2. The crystalline tiotropium bromide of claim 1, furthercharacterized by weight loss of about 5.9% at a temperature of about125° C. to about 184° C. by TGA.
 3. The crystalline tiotropium bromideof claim 1, further characterized by a DSC thermogram having a firstendothermic peak at 158° C., and a second endothermic peak at about 229°C.
 4. A micronized form of Tiotropium bromide, according to claim
 1. 5.A pharmaceutical formulation comprising the form of Tiotropium bromideaccording to claim 1, and a pharmaceutically acceptable excipient.
 6. Apharmaceutical formulation comprising micronized Tiotropium bromide ofclaim 4, and a pharmaceutically acceptable excipient.